Web heating and pressing apparatus

ABSTRACT

Hot stamping apparatus and embossing apparatus for the production of holographic images on a substrate web, each apparatus comprising a heated roll and an anvil each having trunnions at its ends journalled for rotation in bearings in a frame with a cooling system for cooling the bearings for all the trunnions and for cooling the trunnions of the heated roll.

BACKGROUND OF THE INVENTION

This invention relates to web heating and pressing apparatus, moreparticularly to such apparatus comprising a heated roll and a backing oranvil roll between which superimposed webs are fed for pressurizedheat-transfer contact of the heated roll with one of the webs, andspecifically to such apparatus for use in the application of foil areasand the embossing of the foil areas for the production of holographicimages on a substrate web such as a paper web.

Reference is made to U.S. Pat. No. 5,464,690, issued Nov. 7, 1995,entitled Holographic Document and Method for Forming, hereinafterreferred to as the '690 patent, and incorporated herein by reference,showing in FIG. 6 thereof a document having a security holographic imagethereon to prevent counterfeiting, reference being made in column 4,lines 1-3 of this patent to the document being a stock certificate orcheck, or any other desired document upon which it is desired to haveembossed a diffraction grating image or a hologram. The document isdescribed in the '690 patent as comprising a substrate of plain orprinted paper, coated paper or plastic film (the "document substrate")having a "chip" bearing the holograph image identified by the referencenumeral 16.

As illustrated in FIG. 4 of the '690 patent, a continuous web 20 (the"document substrate"), which is ultimately segmented into individualsheets constituting the documents, is intermittently fed forward througha stamping station wherein a composite sheet or web 10 of the so-called"x-factor" construction including foil layer C is intermittently fedover web 20 transversely thereof and, during dwell intervals, a hotstamping head 26 carrying a die 28 is driven down to press down on thecomposite sheet 10 causing a portion of the composite strip constitutingthe "chip" 10¹ to adhere to the web 20. The chip 10¹, adhering to theweb 20, separates from the composite sheet, and the web 20 with chips10¹ adhered thereto feeds forward through an embossing station whereeach chip (having the foil layer C) is embossed to produce the hologramimage thereon. FIG. 5 of the '690 patent shows an alternative procedurewherein the web 20 is continuously fed forward with the composite sheetor web 10 superimposed on the web 20 and extending in the same directionas the web 20, the composite sheet or web 10 having heat and pressureapplied thereto to punch out chips 10¹ from the composite sheet andcause them to adhere to the web, each chip having the foil layer C whichis subsequently embossed to produce the holographic image thereon.

This invention involves apparatus for use in an installation forcontinuous feed therethrough of the paper or film substrate, which maybe referred to as the base web, with the chip-forming web (which may bereferred to as the foil web) thereon for carrying out the stampingoperation at the stamping station to stamp or punch out the chips andcause them to adhere to the base web, ahead of the embossing station,and apparatus for use in the installation at the embossing station forembossing the chips. In respect to the function of the stampingapparatus to apply heat and pressure in the limited area of the foilweb, and the function of the embossing apparatus to apply heat andpressure in the limited area of each chip, apparatus of this inventionis herewith broadly entitled "Web Heating and Pressing Apparatus",noting also that it is contemplated that the principles of the apparatusmay be applicable to apparatus other than the herein-disclosed apparatusfor stamping the foil web superimposed or the substrate on the base weband the apparatus for embossing the chips.

Reference is also made to U.S. Pat. No. 5,618,378 issued Apr. 8, 1997,entitled Apparatus for Applying Images, Particularly Security Images toBanknotes, hereinafter referred to as the '378 patent, and incorporatedherein by reference, involving apparatus for applying a series of images(holographic security images) to moving stock (material in sheet or webform), especially for its disclosure of what may be termed "incrementalfeed" of the images, i.e. feed of closely spaced images onto the movingstock at intervals greater than the spacing of the images. This '378reference is incorporated herein by reference since the above-describedinstallation in which stamping apparatus of the present invention may beused may utilize the "incremental feed" principle thereof for feedingthe foil web to said stamping apparatus.

Reference is made further to the co-assigned U.S. Pat. No. 5,058,496issued Oct. 22, 1991, entitled Roll Apparatus with Cooling System forMaintaining Constant Gap Size and Method, hereinafter referred to as the'496 patent, showing a die cutter comprising a pair of rolls each havingtrunnions at its ends journalled for rotation in bearings in the framewith a cooling system for the bearings wherein a coolant is pumpedthrough the bearings and the temperature of the coolant is controlled bya temperature sensor associated with the frame. This '496 patent isincorporated herein by reference since the present invention may utilizea similar coolant temperature control system.

Reference is also made to U.S. Pat. No. 4,519,757 issued May 28, 1985,entitled Web Surface Treating Apparatus, hereinafter referred to as the'757 patent, showing apparatus including heated rolls 5, 7 and 9 eachconstructed for circulation of heated liquid therethrough. This '757patent is incorporated herein by reference since the present inventionmay utilize similar heated rolls.

BRIEF SUMMARY OF THE INVENTION

Among the several objects of the invention may be noted the provision ofweb heating and pressing apparatus comprising a heated roll and an anvilroll between which web material is fed for application of heat andpressure thereto, said rolls having trunnions journalled in bearings,with a cooling system for cooling the bearings of both rolls and thetrunnions of the heated roll to reduce transfer of heat to the frame fordimensional stability of the frame; the provision of such apparatus,more particularly stamping apparatus for the application of foil areas("chips") on a substrate web, such as a web of paper or film web for theproduction of holographic images thereon; the provision of suchapparatus, more particularly embossing apparatus, for embossing eachchip with a holographic image; and the provision of such apparatuscapable of relatively high speed operation in the production of thesubstrate web with the chips for subsequent embossing of the chips andthe embossing of the chips, needing adjustment relatively infrequently.

In general, web heating and pressing apparatus of this inventioncomprises a frame, a heated roll and an anvil roll each having trunnionsat its ends journalled for rotation in bearings in the frame with theaxes of the rolls at least substantially parallel and with the rolls somounted as to provide a web pass plane between the rolls, and a coolingsystem for cooling the bearings for the trunnions of the heated roll,for cooling the bearings for the trunnions of the anvil roll and forcooling the trunnions of the heated roll. The cooling system comprisespassaging for flow of coolant in heat-transfer relation with thebearings for the trunnions of the heated roll, passaging for flow ofcoolant in heat-transfer relation with the bearings for the trunnions ofthe anvil roll, and a cooling chamber for flow of coolant therethroughin heat-transfer relation to the trunnions of the heated roll, saidpassaging and cooling chamber being connected in a circuit forcirculation of coolant therethrough for cooling the bearings for thetrunnions of both rolls and the trunnions of the heated roll.

Other objects and features will be in part apparent and in part pointedout hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view in plan of an equipment layout includingstamping apparatus of this invention for stamping out chips from a webof foil and causing the chips to become adhered to a substrate web, andembossing apparatus of this invention for embossing the chips, partsbeing omitted;

FIG. 2 is a view in side elevation of FIG. 1 taken on line 2--2 of FIG.1 from the side thereof referred to as the operator's side, parts beingomitted;

FIG. 2A is a view of a fragment of the foil web after stamping;

FIG. 3 is a view in side elevation of stamping apparatus of thisinvention taken from the other side from that shown in FIG. 2, referredto as the drive side;

FIG. 4 is a view in side elevation of the stamping apparatus taken fromthe operator's side of the apparatus, with parts broken away to showinterior detail;

FIG. 5 is a plan view of the stamping apparatus, showing circuitry forcirculation of hot oil through the heated roll thereof for heating it,parts being omitted;

FIG. 6 is a view in elevation of the stamping apparatus on line 6--6 ofFIG. 1, with parts omitted and parts broken away and shown in section;

FIG. 7 is an enlarged part of FIG. 6 with parts further broken away andshown in section;

FIG. 8 is a view showing detail of the heated roll of the stampingapparatus, with parts broken away and shown in section;

FIG. 8A is an enlarged fragment of FIG. 8;

FIG. 9 is a view in section on line 9--9 of FIG. 8;

FIG. 10 is an enlarged fragment of FIG. 7;

FIG. 11 is a view in section on line 11--11 of FIG. 10;

FIG. 12 is an enlarged fragment of FIG. 10;

FIG. 13 is a semi diagrammatic view generally on line 13--13 of FIG. 5showing part of the hot oil circuitry for heating the heated roll;

FIG. 14 is a diagrammatic view of the coolant circuitry; and

FIG. 15 is a view of the heated roll and the anvil roll of the embossingapparatus of the invention with the anvil roll partly broken away andshown in section.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DETAILED DESCRIPTION

Referring first to FIGS. 1 and 2 of the drawings, equipment for theproduction of a continuous web W, such as the web 20 shown in the '690patent with holographic images H such as the images indicated at 16 inthe '690 patent at equally spaced intervals lengthwise thereof, is shownas comprising a stamping station S and an embossing station Ecorresponding generally to the stamping station 22 and embossing station23 of the '690 patent. The web W is continuously fed forward by andbetween a pair of rolls 5 and 7 of stamping apparatus of this inventionat the stamping station and a pair of rolls 9 and 11 of embossingapparatus of this invention at the embossing station. The stampingapparatus is designated in its entirety by the reference numeral 1 andthe embossing apparatus is designated in its entirety by the referencenumeral 3. The web W, which may be hereinafter referred to as thesubstrate web, e.g. a web of paper or plastic film constituting the"document substrate" or "document web", is fed continuously, from leftto right as shown in FIGS. 1 and 2, through these stations. A web F,which may be hereinafter referred to as the foil web, having thex-factor component 10 of the '690 patent with the overlying filmsubstrate A such as described in the '690 patent (shown in FIG. 1thereof) is fed into overlying relationship with the web W as the latterenters rolls 5 and 7 at the stamping station 1.

As the webs W and F pass between these rolls 5 and 7, chips Ccorresponding to chips 10 shown in the '690 patent are stamped from thefoil web F onto the web W, the chips C being spaced lengthwise of theweb W at intervals corresponding to the length of individual sheets intowhich web w is ultimately segmented. The chips C are adhered to the webW. The foil web F minus the chips C ("F-C") exiting the rolls 5,7 isrewound and may ultimately be recycled. The areas from which the chips Care removed are shown in FIG. 2A as windows 13 corresponding to windows17 shown in the '690 patent spaced at intervals along the length of theF-C web. The web W with the chips C thereon exiting from the rolls 5 and7 passes through rolls 9 and 11 of embossing apparatus of this inventionat the embossing station 3 where a holographic image H corresponding toimage 16 of the '690 patent (a diffraction grating image) is embossedinto the exposed surface of the chips, thus completing the production ofthe continuous substrate web W with the holographic images H at equallyspaced intervals (sheet-length intervals) thereon.

The present invention involves the stamping apparatus generallydesignated 1 used at the stamping station S for hot stamping the foilweb F to stamp out the chips C therefrom and cause them to becomeadhered to the web W and the embossing apparatus generally designated 3used at the embossing station E for embossing the chips. The stampingapparatus 1 and embossing apparatus 3 are generally identical (thedifferences to be subsequently described); and the stamping apparatus 1will be described first. Referring now to FIGS. 3-7, the stampingapparatus 1 is shown to comprise a frame designated in its entirety bythe reference numeral 21, and more particularly to comprise side framemembers 25a and 25b "a" referring to what is termed the drive side and"b" referring to what is termed the operator's side of the stampingapparatus. In FIGS. 6 and 7, 25a appears at the left; in FIG. 6, 25bappears at the right, 25a being omitted. The frame includes a cross-bar25c of channel shape in cross-section extending between the side framemembers secured to the insides thereof as indicated at 25d, rigidlyholding the side frame members in their spaced-apart vertical parallelrelation. Roll 5 previously referred to is a heated roll havingtrunnions at its left and right ends as shown in FIG. 6, its left endbeing its end toward the drive side of the apparatus and its right endbeing its end toward the operator's side of the apparatus. The trunnionsare identical, each being designated 27. They are journalled forrotation in bearings each generally designated 29 in the side framemembers with the axis of the roll 5 generally horizontal.

Roll 7 previously referred to, paired with roll 5, is a backing or anvilroll having trunnions each designated 31 at its left and right ends asshown in FIG. 6 journalled for rotation below roll 5 in bearings eachgenerally designated 33 in the side frame members 25a, 25b with the axisof roll 7 generally horizontal and generally parallel to the axis ofroll 5, with the rolls so mounted as to provide a generally horizontalpass plane P between the rolls for passage of the web F as a first websuperimposed on the web W as a second web between the rolls withpressurized heat-transfer contact of the heated roll 5 over two raisedareas 5A and 5B thereof each corresponding to the area of a chip C to beformed from the web F superimposed on the web W backed by the anvil roll7. These raised areas 5A and 5B, which are spaced at 180° intervalsaround the surface of the heated roll (see particularly FIG. 9) in thetransverse plane of the heated roll where the chips C are to be appliedfunction as stamping dies corresponding to the dies 23 and 45 of the'690 patent. The anvil roll 7 may be a steel roll or ahard-rubber-surfaced roll (e.g. 90 Shore "A" durometer rubber).

Each of the bearings 29 for the trunnions 27 of the heated roll 5comprises a cylindric bearing housing indicated in its entirety by thereference numeral 35 mounted in the respective side frame member 25a,25b. Referring to FIG. 7, bearing 29 is shown as comprising an outerrace 37 mounted in the housing 35, an inner race 39 in the outer racefixed on the respective trunnion 27, with an annular space 41 betweenthe races, and rolling elements, more particularly rollers 43, betweenthe races, the bearing being a tapered roller bearing.

Each of the bearings 33 for the trunnions 31 of the anvil roll 7comprises a cylindric bearing housing indicated in its entirety by thereference numeral 45 mounted in the respective side frame member 25a,25b. Each bearing 33 comprises an outer race 47 mounted in the housing45, an inner race 49 in the outer race fixed on the respective trunnion31 with an annular space 51 between the races, and rolling elements,more particularly rollers 53, between the races, the bearing being atapered roller bearing.

The side frame members 25a, 25b extend up from a base plate 55 on whichthey are fastened down by clamps as indicated at 57. The base plate issupported on a table structure 58. The frame 21 (side members 25a, 25band cross-bar 25c) are adjustable laterally with respect to theapparatus on the base plate, the clamps being loosened, by meansindicated at 59 including an adjusting screw 61 associated with the sideframe member 25b on the operator's side of the apparatus and a handwheel63 for turning the screw, with a clamp indicated at 65. Each bearinghousing 33 is mounted in a block 67 seated in fixed position in therespective side frame member 25a, 25b at the lower end 69 of the lowerpart 71a of a slot, designated 71 in its entirety extending down in theside frame member from its upper end. Each bearing housing 35 is mountedin a block 73 vertically slidable in a wider upper part 71b of the slot71 above the block 67. The block 73 has side guides 74 guiding it for upand down movement in the slot. Each of the lower blocks 67 is releasablyheld in fixed position seated in the lower part 71a of slot 71 by screwsindicated at 67a accessible through holes indicated at 67b in the sideframe members 25a, 25b. Each of the upper blocks 73 has stop spacers 73aat the bottom thereof engageable with step 71c of the slot 71determining its fixed position in the upper part 71b of the slot 71.

Each side frame member 25a, 25b has a head 75 at its upper end. On eachhead is an air cylinder 77 having piston rod 79 extending down from thepiston (not shown) therein through an opening 81 in the head 75, thepiston rod having a cross-head structure 83 at its lower end releasablyfastened by screws 83a to the respective block 73. Pressurized air issupplied to the upper ends of the air cylinders above the pistonstherein to push the blocks 73 down to their fixed position determined byspacers 73a thereby to hold down the bearings 29, the trunnions 27 andthe heated roll 5. The air cylinders 77 may also be utilized to pullblocks 73 up to lift roll 5 off roll 7 as on shut-down of the apparatus,the lift being limited by screw stops 78.

Each block 73 is formed for releasably clamping the respective upperbearing housing 35 therein, being of rectangular outline with agenerally circular opening 85 therein receiving the respectivecylindrical bearing housing 35, and being split as indicated at 87 atthe top. Each block 73 is provided with a clamp screw 89 having a knob91 at its outer end for drawing together the upper parts of the block atthe split for clamping the respective bearing housing 35 therein.

Each block 67 is similarly formed for releasably clamping the respectivelower bearing housing 33 therein, being of rectangular outline with agenerally circular opening 93 therein receiving the respective bearinghousing 45 and being split as indicated at 95 at the top of the block.Each block 67 is similarly provided with a clamp screw 97 having a knob99 at its outer end for drawing together the upper parts of the block atthe split for clamping the respective bearing housing 33 therein. Eachof the bearing housings 33 is rotatable on a generally horizontal axisin its block 67 with the block loosened, and the axis of the bearing inthe housing (the axis of the trunnion 31) is slightly eccentric withrespect to housing axis.

At 101 in FIG. 4 is generally indicated means for rotating each of thebearing housings 45 in the respective blocks 67 on the axis of thehousing for up and down adjustment of the eccentric axis of the bearingwith respect to the respective block and hence the frame 21. This means101 comprises a shaft 103 extending horizontally across the apparatusjournalled adjacent its ends in the side frame members and havingpinions 105 thereon on the inside of the side frame members in mesh 20with gear segments 107 on the respective bearing housings. The shaft isrotatable one way and the other by a crank 109 on its end at theoperator's side of the apparatus. At 111 is indicated an eccentrichousing to remove backlash from gear set 105/107. A gauge constituted bya disk 113 on the shaft on the outside of side frame member 25b and apointer 115 on member 25b is provided for reading the elevation of theaxis. See FIG. 2 for markings on the disk as indicated at 116.

The rolls 5 and 7 are driven in the direction for feeding webs W and Fforward, i.e. in the direction from left to right as shown in FIGS. 1, 2and 4, by an electric motor 117 via a timing belt and pulley driveindicated at 119, including a pulley 121 on the outer end of the driveside trunnion 31 of the roll 7, and gearing 123 for driving roll 5 fromroll 7 with roll 5 driven counterclockwise as viewed in FIGS. 2 and 4and roll 7 driven clockwise. The motor 117 is mounted on a bracket 125on the left-hand (drive side) side frame member 25a. The gearingcomprises a gear 127 on the left-hand trunnion 31 of the anvil roll 7meshing with a gear 129 on the left-hand trunnion 27 of the heated roll5. Means for tensioning the timing belt of the belt and pulley drive 119is indicated at 130.

The heated roll 5 comprises a relatively thin-walled hollow cylindricalshell or sleeve 131, telescoped on and surrounding a generally cylindriccore 133, both of steel for example (see particularly FIGS. 8 and 9).The shell is longer than the core and has end portions 135 which extendbeyond the core at both ends of the core. The core has a multiplicity ofgrooves 137 extending in axial direction with respect to the core fromone end to the other end thereof in its periphery. The shell 131 isshrunk on the core 133 so that its internal cylindrical surface 139contacts to the external surfaces of the ribs or lands 141 on the corewhich bound the grooves 137 at opposite sides of the grooves, wherebythe grooves in conjunction with the shell form channels also designated137 extending lengthwise of the heated roll adjacent the peripherythereof for flow therethrough of hot liquid, more particularly hot oil,from one end of the heated roll to the other (from its left end to itsright end as illustrated in FIG. 8). The construction of the heated roll5 is similar to that of the heated rolls described in the above-noted'757 patent, to which reference may be made for further details.

Each of the trunnions 27 of the heated roll 5 comprises an elongatetubular cylindric shaft 143 having what may be termed a head designatedin its entirety by the reference numeral 145 at one end thereofconstituting its inner end with respect to the roll 5, said headcomprising an outer circular plate or disk 147 having a diametercorresponding to the internal diameter of the shell 131. Each disk 147,which constitutes an end head or end wall for the heated roller 5, has acylindrical boss 149 coaxial therewith (and coaxial with the shaft 143)on the side thereof (its inner side) toward the core 133. The boss is ofdisk-like form having a flat circular inner face 151 engaging therespective end of the core (each end of the core being flat in a planetransverse to the axis of the core).

The disk 147 of the end head 145 of each shaft 143 is fitted in therespective projecting end 135 of the shell to the point where the face151 of the boss 149 engages the respective end of the core 133, has anannular peripheral recess 153 at the outside peripheral edge thereof,and is welded in the projecting end 135 of the shell by weldment in thisrecess as indicated at 155. With each trunnion end head 145 soconstructed and so arranged and welded in the ends of the shell 131, theheated roll 5 has an annular space or chamber 157 surrounding each boss149, each chamber being defined by the outer periphery of the boss, theface of the disk 147 opposed to the end of the core 133, and the insideannular surface of the projecting end 135 of the shell and the end faceof the core.

Each of the trunnion shafts 143 and the respective head 145 have anaxial bore designated in its entirety by the reference numeral 159, saidbore having an elongate portion 159a extending from the outer end of theshaft to the inner end of the shaft and partly into the outer disk 147,and a stepped-down portion 159b (i.e. a portion of smaller diameter thanportion 159a) extending centrally through the outer disk with acontinuation 159c of portion 159b in the boss, all terminating in acentral recess 159d in the core. The elongate portion 159a of bore 159in the shaft 143 is lined from one end thereof to the other with thermalinsulation material, preferably TEFLON, as indicated at 161.

Each boss 149 has radial passages 163 extending between the continuation159c of the bore 159 and the periphery of the boss providingcommunication between the inner end of the bore in the respectivetrunnion 27 and the respective chamber 157. The arrangement is such asto provide for flow of oil to the heated roll 5 through the bore 159 ofone of the trunnions, herein the left-end trunnion as shown in FIGS. 6and 7 on the drive side of the apparatus, through the radial passages163 in the boss 149 at the left end of the roll 5 to the space 157around the left-hand boss constituting an annular manifold incommunication with channels 137, thence through these channels to theannular space 157 surrounding the boss at the right-hand end of the roll5, thence inwardly through the radial passages 163 in the boss at theright-hand end of the roll 5, and out through the bore 159 in theright-hand trunnion 27. The space 157 in the heated roll 5 at its rightend may be referred to as an annular manifold for receiving the oilflowing out of the right-hand ends of the channels 137.

Each trunnion 27 extends outward from the respective end of theshell/core assembly 131, 133 coaxially therewith, and has a rotarycoupling element 165 of a rotary union 167 secured thereon at its outerend. This rotary coupling element 165 is rotary in a fixed rotarycoupling element 169 for connection of the heated roll 5 in a hydraulicsystem or circuit shown in FIGS. 5 and 13 indicated in its entirety bythe reference numeral 171 for flow of heated liquid (e.g. oil) throughthe channels 137 in the roll for heating the shell 131 thereof.Referring to FIGS. 5 and 13, the stated hydraulic circuit 171 is shownto comprise an oil tank 173 having means diagrammed at 175 for heatingthe oil therein to a predetermined desired temperature, an oil deliverypipe line 177 for delivery of oil from the tank to the fixed rotarycoupling element 169 for the trunnion 27 on the drive side of theapparatus, and an oil return pipe line 179 for return of oil to the tankfrom the fixed rotary coupling element 169 for the trunnion 27 on theoperator's side of the apparatus, the circuit including a pumpdiagrammed at 176 for pumping heated oil from the tank 173 through pipeline 177, the trunnion 27 on the drive side of the apparatus, throughthe passages 163 of the boss 149 and the annular manifold 157 on thedrive side of the apparatus, from left to right through the channels 137in the heated roll 5, and the manifold 157 and passages 163 at theoperator's side of the apparatus, the trunnion 27 on the operator's sideof the apparatus, and thence through the oil return pipe 179 to thetank. Tank 173 may be a TUC heater sold by TUC of Holland, Mich.

As above described, the heated roll 5 has the two raised areas 5A and 5Bon the shell 131 functioning as heated dies for effecting the hotstamping of the foil web F, these raised areas being spaced at 180°intervals around the periphery of the shell to stamp out chips C fromweb F with the chips becoming adhered to the web W spaced at intervalsalong the length of the web. With the two dies 5A, 5B spaced at 180°around the shell, the chips are spaced along the length of the web w atintervals corresponding to half the circumference of the shell of theheated roll. The raised areas or dies 5A and 5B are very thin inrelation to the diameter of the heated roll; for example, in a physicalembodiment of the apparatus wherein the heated roll has an overalllength of 18 inches (for handling webs W up to 16 inches wide) and anexternal diameter of approximately 7.632 inches, the outside surface ofeach die which contacts the foil web F on each revolution of roll 5 israised 0.014 inch from the cylindrical outer surface of the shell of theroll 5, and, as shown, may be of square outline approximately 0.600 inchon a side with corners rounded on a radius of 0.045 inch and having a 5RMS finish as shown in FIGS. 6, 8 and 8A. The apparatus with the stateddimensions for the heated roll and with the two dies spaced at 180°intervals around the roll applies chips C approximately 0.600 inchsquare at approximately twelve inch intervals (one-half thecircumference of roll 5) to the web W for ultimate cutting of web W intosheets twelve (one-half of 7.632π) inches long each bearing a hologram.

A cooling system designated in its entirety by the reference numeral 181(see FIG. 14) is provided for cooling the bearings 29 for the trunnions27 of the heated roll 5, for cooling the bearings 33 for the trunnions31 of the anvil roll 7 and for cooling the trunnions 27 of the heatedroll 5 in addition to the cooling of the bearings 29. The cooling system181 includes passaging indicated generally at 183 in each of thehousings 35 for the bearings 29 for flow of oil as a coolant andlubricant to one side of the space 41 between the inner and outer races39 and 37 of the bearings, thence through said space and thence fromsaid space out of the housing. Passaging 183 has an inlet 185 fordelivery of coolant to an annular space 187 at one side of the races andan outlet 189 for exit of coolant from an annular space 191 at the otherside of the races.

The cooling system 181 further includes passaging indicated generally at193 in each of the housings 45 for the bearings 33 for flow of oil as acoolant and lubricant to one side of the space 51 between the inner andouter races of these bearings, thence through said space and thence fromsaid space out of the housing 45. Passaging 193 has an inlet 195 fordelivery of coolant to an annular space 197 at one side of said racesand an outlet 199 for exit of coolant from an annular space 201 at theother side of said races.

For cooling each of the trunnions 27 of the heated roll 5, the coolingsystem 181 includes an annular body 203 (see FIGS. 6, 7, 10 and 11)surrounding each trunnion attached to the side of the respective bearinghousing 35 toward the respective end of roll 5 (the inner side of thebearing housing). Each of these annular bodies 203 has a cooling chamber205 formed by an internal annular recess therein surrounding therespective trunnion for flow therethrough of coolant in heat-transferrelation with the respective trunnion 27 for direct cooling of thetrunnion in the region thereof between the respective bearing housing 35and the respective end of the heated roll. Preferably, in accordancewith this invention, each cooling chamber 205 has a helical rib or fin207 therein extending from one end thereof to the other constituting ahelical flow director forming a helical channel 209 around therespective trunnion 27 for flow of coolant through the cooling chamberin a helical path around the respective trunnion. Each cooling chamber205 is located adjacent the respective end of the heated roll 5 betweenthe respective end of the heated roll and the respective bearing housing35 for effecting cooling of the respective trunnion 27 immediatelyoutward of the respective end of the heated roll. As shown in FIG. 10and in enlarged detail in FIG. 12, each trunnion 27 of the heated roll 5is machined to have an external screw thread 211 over a portion of thelength thereof within the cooling chamber 205, the helical rib 207 inthe cooling chamber having an internal diameter slightly greater (e.g.0.016" greater) than the external diameter of the screw-threaded portionof the trunnion. The coolant flows from inlet 213 in the cooling chamberbody 203 at one end of the cooling chamber 205 in a helical path aroundthe respective trunnion 27, also axially in a turbulent state in theclearance 212 between the screw-threaded portion of the trunnion and theinner edge of the helical rib or fin 207 from inlet 213 at said one endof the cooling chamber to coolant outlet 215 at the other end of theannular cooling chamber. The screw thread 211 causes turbulence in theaxial flow of coolant for augmenting the heat transfer.

As illustrated, only the trunnions 27 of the heated roll 5 have thecooling chamber bodies 203 and cooling chambers 205. No such chambersare provided for the trunnions of the anvil roll 7 since the anvil rollis not heated and its trunnions do not need the special cooling featureprovided for trunnions 27.

The cooling system 181 as shown in FIG. 14 includes a source 217 ofliquid coolant, oil being preferred and serving as a lubricant as wellas coolant for the bearings, which comprises means diagrammed at 219 forcooling the coolant and a pump diagrammed at 221 for pumping the coolantthrough a coolant delivery line 223 including a pressure gauge 225 to amanifold 227. Source 217 may be a Koolout Kooler sold by Koolant Kooler,Inc. of Kalmazoo, Mich. Coolant delivery lines 229, 231 and 233 extendfrom the manifold to inlet 185 of the drive side bearing housing forpassaging 183 therein, to inlet 195 in the drive side bearing housingfor passaging 193 therein, and to inlet 213 in the drive side coolingchamber body 203 for channel 209 therein. Similarly, coolant deliverylines 235, 237 and 239 extend from the manifold 227 to the inlet 185 ofthe operator's side bearing housing for passaging 183 therein, to inlet195 in the operator's side bearing housing for passaging 193 therein,and to inlet 213 in the operator's side cooling chamber body 203 forchannel 209 therein. Coolant return lines 241, 243 and 245 extend fromthe drive side outlets 189, 199 and 215 to a return line manifold 247.Similarly, coolant return lines 249, 251 and 253 extend from theoperator's side outlets 189, 199 and 215 to the return line manifold. Acoolant return line 255 extends from the return manifold to the coolantsource 217, this line including pressure gauge 257. Each of the sixcoolant delivery lines includes a needle valve 259 for regulating therate of flow through the line and a flow meter 261.

Preferably, the stamping apparatus 1 comprises means for controlling thetemperature of the coolant delivered by the coolant source 217 includinga temperature sensor 263 (see FIG. 4) associated with the frame 21 andmeans responsive to the temperature sensor for controlling the coolanttemperature to maintain a predetermined temperature differential betweenthe temperature of the frame and the temperature of the coolant, withthe coolant temperature lower than the frame temperature. This controlmeans may correspond to that shown in the above-noted coassigned '496patent, incorporated herein by reference, the temperature sensor 263corresponding to the temperature sensor 56 of the '496 patent, referencebeing made to that patent for details of the control system includingthe temperature sensor mounted on the frame.

In the operation of the stamping apparatus 1 and the embossing apparatus3, substrate web W is fed continuously forward (from left to right asshown in FIGS. 1, 2 and 4) at a predetermining speed by and between theheated roll 5 and the anvil roll 7, these rolls being driven by themotor 117 in forward feed direction as shown by the arrows in FIGS. 2and 4. The web W travels over a guide roller 264. The foil web F is fedforward in increments of lesser length than the spacing of the chips Cby a foil feeder and rewinder apparatus indicated at 265 in FIGS. 1 and2, such as a Incremental Foil Feeder sold by UITS-America, Inc. ofBlauvelt, New York, constructed and operable in the manner of the ribbonfeed and rewinder shown in the above-noted '378 patent, incorporatedherein by reference. The foil feeder and rewinder apparatus at 265 feedsthe foil web F from a roll indicated at FR in FIG. 1 (indicateddiagrammatically at FR in FIG. 4) around guide rollers including roll267 shown in FIG. 4 generally at the level of the pass plane of rolls 5and 7 into overlying relationship with the web W as the latter entersrolls 5 and 7. In operation of the stamping and embossing apparatus toapply chips C 0.600 inch square spaced at twelve-inch intervals, forexample, the foil web F may be fed forward in one-inch increments, forexample, with the result that in the F-C web (foil web minus chips)exiting the rolls 5, 7 the windows 13 (0.600 inch square) are spaced atone-inch intervals along the length of the F-C web center-to-center.Feeding the foil web in such increments, instead of feeding twelveinches of the foil web for each twelve inches of the substrate web,greatly reduces the amount of F-C web needing recycling. The foil feederand rewinder apparatus is secured on the frame 25 as indicated at 269 inFIGS. 1 and 2.

As the webs F and W are fed forward between rolls 5 and 7, web F beingsuperimposed on web W off-center with respect to web W in line with thestamping dies 5A and 5B on roll 5, on each successive half-revolution ofroll 5, the hot die 5A stamps out a chip C and the hot die 5B stamps outa chip C, the chips becoming adhered to web W spaced at intervals equalto half the circumference of roll 5 (e.g. twelve-inch intervals).Generally, the foil web F is pressed to some extent across its widthinto web W (backed by the anvil roll) and pressed farther into web W byeach die over the area of the die. It may be efficacious to constructthe anvil roll with a relatively hard but yielding rubber surface (e.g.rubber of 90 Shore "A" durometer) to enable stamping of the chips whilemaintaining contact of the rolls with web W across its width in the passplane of the rolls.

The web W with chips C thereon spaced at intervals (e.g. sheet-lengthintervals) travels forward from the nip of rolls 5 and 7 under a guideroller 271 mounted on arms 273 extending forward from the side framemembers 25a, 25b and thence through the embossing rolls 9 and 11 of theembossing apparatus 3, as shown in FIGS. 1 and 2, for embossing thechips C with holographic images as above stated. The F-C web issuingfrom rolls 5, 7 is rewound as indicated at 275 in FIGS. 2 and 4 by thewinding means of the foil feeder and rewinder 265.

As above described, hot oil is circulated through the roll 5 for heatingit at the periphery thereof, especially for heating the stamping dies 5Aand 5B. In the above-noted physical embodiment of the invention, forexample, the oil is heated generally to a temperature of 360° F. Oil ascoolant and lubricant is circulated through the bearings 29 for thetrunnions 27 of the heated roll 5, through the bearings 33 for thetrunnions 31 of the anvil roll for cooling these bearings, and througheach of the cooling chambers 205 in the stated helical path of thehelical channel 209 therein around each trunnion 27 and axially in aturbulent state in clearance 212 for cooling each trunnion 27 in theregion between the respective end of the roll 5 and the respectivebearing 29. Since the anvil roll 7 is not heated, the rate of flowthrough its bearings 33 is preferably less than the rate of flow throughthe bearings 29 for the heated roll; for example, oil at 64° F., may becirculated through bearings 29 at the rate of approximately 2 gallonsper minute and through bearings 33 at the rate of approximately 0.6gallons per minute. Also, the rate of flow through chambers 205 ispreferably higher than the rate of flow through bearings 29, beingapproximately 5 gallons per minute, for example. These rates may be setby the valves in the coolant delivery lines. The temperature of thecoolant is controlled by sensor 263 and the means associated with saidsensor such as disclosed in the '496 patent for maintaining apredetermined temperature differential between the frame and coolanttemperatures.

The embossing apparatus 3 is essentially identical to the stampingapparatus 1, omitting the foil feeder and rewinder apparatus 265, havingits own cooling system corresponding to the cooling system 181 shown inFIG. 14 for the stamping apparatus and its own heating system for itsroll 9 corresponding to the hot oil circuit 171 shown in FIG. 13 for thestamping apparatus, and having hologram embossing dies such as indicatedat 276 in FIG. 15 on the roll 9 in place of stamping dies 5A and 5B, theembossing dies being engraved to emboss chips C each with a holographicimage. Preferably the anvil roll 11 of the embossing apparatus has arelatively hard rubber surface, e.g. 60 Shore "D" durometer rubber asindicated at 278 in FIG. 15, the rubber comprising a surface layer fromabout 0.010 to 0.100 inch thick on a steel roll, the holographicembossing being improved by use of an anvil roll with such a hard rubbersurface. Further differences involve omission of roll 264, making knob99 closer to the frame, and provision of roll 277 as shown in FIG. 2instead of roll 271. Operation of the embossing apparatus in phase withthe operation of the stamping apparatus is effected in suitable mannernot constituting part of the present invention.

As to each of the stamping and embossing devices 1 and 3, with thetrunnions 27 of the heated roll 5 cooled as described in addition to thecooling of the bearings of each of the rolls 5 and 7, and with the otherfeatures of the devices as above described, the several objects of theinvention are achieved and other advantageous results attained.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. Web heating and pressing apparatus comprising:a frame; a heated roll and an anvil roll each having trunnions at its ends journalled for rotation in bearings in the frame with the axes of the rolls at least substantially parallel and with the rolls so mounted as to provide a web pass plane between the rolls; a cooling system for cooling the bearings for the trunnions of the heated roll, for cooling the bearings for the trunnions of the anvil roll, and for cooling the trunnions of the heated roll, said system comprising:passaging for flow of coolant in heat-transfer relation with each of the bearings for the trunnions of the heated roll, passaging for flow of coolant in heat-transfer relation with each of the bearings for the trunnions of the anvil roll, and cooling chambers for flow of coolant therethrough in heat-transfer relation to the trunnions of the heated roll, said passaging and cooling chambers being connected in a circuit for circulation of coolant therethrough for cooling the bearings of each roll and the trunnions of the heated roll.
 2. Apparatus as set forth in claim 1 wherein each cooling chamber is formed by an internal annular recess in an annular body surrounding the respective trunnion of the heated roll, coolant in the chamber being in direct heat-transfer contact with the periphery of said respective trunnion.
 3. Apparatus as set forth in claim 2 wherein said cooling chamber has flow director means therein for flow of coolant through the chamber in a helical path around the respective trunnion.
 4. Apparatus as set forth in claim 3 wherein the flow director means in each cooling chamber comprises a helical rib in said chamber forming a helical channel around the respective trunnion.
 5. Apparatus as set forth in claim 4 having clearance between each helical rib and the portion of the respective trunnion extending therethrough for axial flow of coolant through said clearance.
 6. Apparatus as set forth in claim 5 wherein said portion of each trunnion is formed to cause turbulence in the axial flow of coolant.
 7. Apparatus as set forth in claim 6 wherein said portion of each trunnion is screw-threaded to cause said turbulence.
 8. Apparatus as set forth in claim 2 wherein each of said annular bodies is located adjacent the respective end of the heated roll surrounding the respective trunnion between the respective end of the heated roll and the bearing for the respective trunnion.
 9. Apparatus as set forth in claim 8 wherein each annular body is fastened to the respective bearing on the inside thereof.
 10. Apparatus as set forth in claim 1 wherein each of the bearings for the trunnions of each roll comprises a bearing housing mounted in the frame, an outer race in the housing, an inner race in the outer race fixed on the respective trunnion with an annular space between the races, and rolling elements between the races, each housing including passaging for flow of coolant through the space therein from one side of said space to the other.
 11. Apparatus as set forth in claim 1 employing oil as the coolant wherein said circuit comprises an oil cooler, oil lines for delivery of oil from said cooler to and through said passaging and said cooling chamber and oil lines for returning oil from said passaging and cooling chamber to the cooler.
 12. Apparatus as set forth in claim 1 having valve means in said circuit for regulating the rate of flow through the first-mentioned passaging to be higher than the rate of flow through the second-mentioned passaging and the rate of flow through the cooling chambers to be higher than the rate of flow through the first-mentioned passaging.
 13. Apparatus as set forth in claim 1 wherein each trunnion of the heated roll is tubular and thereby has a passage for flow therethrough of hot fluid for heating the heated roll, wherein the heated roll is passaged for flow therethrough of the hot fluid from the one trunnion at one end of the heated roll to the other trunnion at the other end of the heated roll in a path such as to provide for heat transfer from the hot fluid to the surface of the heated roll, and wherein the trunnions of the heated roll and the heated roll are connected in a circuit including a source of heated fluid, a fluid delivery line for flow of hot fluid from the source to a rotary fluid union at the outer end of the trunnion at one end of the heated roll, a rotary fluid union at the outer end of the trunnion at the other end of the heated roll, and a fluid return line for flow of fluid from the latter rotary fluid union to said source of hot fluid.
 14. Apparatus as set forth in claim 13 wherein said heated roll comprises a core, a shell on the core having end portions extending beyond the core at each end of the heated roll, the trunnions for the heated roll having heads in the ends of the shell formed to provide annular fluid manifolds in the heated roll at the ends thereof, said heated roll having channels for flow of heated fluid from the manifold at one end thereof to the manifold at the other end thereof on the inside of the shell, said heads being passaged for fluid communication of the passage in each trunnion of the heated roll with the manifold at the respective end of the heated roll, said heated roll having thermal insulation lining in the passages of the trunnions of the heated roll thereof.
 15. Apparatus as set forth in claim 14 having at least one die on the shell for hot pressing web travelling between the rolls over an area of the web.
 16. Apparatus as set forth in claim 1 wherein each of the bearings for the trunnions of the heated roll is maintained at a predetermined elevation in the frame and with the heated roll above the anvil roll, the bearings for the trunnions of the anvil roll are mounted in the frame for adjustment of the elevation of the anvil roll, and wherein the apparatus has means for simultaneous adjustment of the bearings for the trunnions of the anvil roll for adjustment of the elevation of the anvil roll.
 17. Apparatus as set forth in claim 16 wherein the bearings for the trunnions of the heated roll are mounted for up and down movement in the frame, and wherein the apparatus has means pushing the bearings for the trunnions of the heated roll down to a fixed position determinative of said predetermined elevation of said bearings for the trunnions of the heated roll.
 18. Apparatus as set forth in claim 17 wherein said pushing means comprises, for each of the bearings for the trunnions of the heated roll, an air cylinder operable for pushing down on and also pulling up said bearings for the trunnions of the heated roll.
 19. Apparatus as set forth in claim 17 wherein each bearing comprises a cylindrical bearing housing, and wherein each said housing is clamped in a block mounted in the frame, the blocks for the bearings of the anvil roll being mounted in position in the frame, the bearing housing of each of the bearings for the trunnions of the anvil roll being rotatable in the respective block on being unclamped for said adjustment of the elevation of the anvil roll. 